Closed-Loop Hydraulic Flushing with Active Discharge Valve Control
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Solution Overview
Problem
Existing hydraulic systems in mining vehicles face inefficiencies and poor controllability in flushing closed loop hydraulic circuits, leading to unsatisfactory energy use and fluid quality.
Innovation Solution
A flushing system with actively controlled by-pass flow, utilizing a separate hydraulic fluid source for feeding and discharging fluid, managed by a control unit that monitors parameters to ensure precise and energy-efficient flushing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flushing pump driven parallel to the main hydraulic pump is used to produce flushing flow, then the closed loop hydraulic system can be flushed, but energy efficiency deteriorates due to poor energy efficiency
Solution Approach 1:
The main hydraulic pump is designed to perform dual functions: both driving the hydraulic actuators during normal operation and generating flushing flow when needed. This eliminates the need for a separate flushing pump, thereby improving energy efficiency while maintaining flushing capability through active control of the pump's operation mode
Solution Approach 2:
The flushing system merges the flushing function with the main hydraulic pump and control valve system. By integrating the flushing capability into the existing hydraulic circuit control architecture, the system avoids the energy waste of running a separate parallel pump while maintaining effective flushing through controlled by-pass flow
2Reliability
If a separate control valve is used to control flushing flow and pressure, then flushing can be executed, but controllability deteriorates due to unsatisfactory controllability
Solution Approach 1:
The control system incorporates feedback mechanisms that monitor hydraulic circuit parameters and actively adjust the control valve positioning and pump operation. This closed-loop control enables precise regulation of flushing flow and pressure, significantly improving controllability compared to passive or open-loop flushing systems
Solution Approach 2:
The system employs dynamic control of the hydraulic pump and control valve based on real-time operational conditions. The pump's delivery and the control valve's positioning are actively adjusted during flushing operations to optimize flow and pressure control, transforming the static flushing system into a dynamically controllable one
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables effective and accurate control of flushing, improving energy efficiency and fluid quality, allowing only necessary hydraulic pressure and flow to be generated when needed.
Implementation Method 1
pressurized hydraulic fluid is circulated from an outlet port of a hydraulic pump to an inlet port of the hydraulic actuator
Implementation Method 2
pressurized hydraulic fluid is circulated from an outlet port of a hydraulic pump to an inlet port of the hydraulic actuator
Implementation Method 3
The mentioned discharge arrangement comprises at least one discharge valve which is actively controlled under control of at least one control unit and wherein fluid flow through the discharge valve is selectively controllable
Implementation Method 4
a feed arrangement for feeding limited amount of additional hydraulic fluid to the closed loop hydraulic circuit from a separate hydraulic fluid source
Data Source
AI summary
A hydraulic system, mining vehicle, and method for flushing a closed loop hydraulic circuit is provided. The hydraulic system includes at least one closed hydraulic circuit having a hydraulic pump, a motor and one or more hydraulic actuators. The hydraulic system further includes a flushing system arranged for discharging and feeding a limited amount of hydraulic fluid for flushing the closed loop hydraulic circuit. There is a discharge valve, which is actively controlled by a control unit so that fluid flow through the valve is selectively controlled.